Designing & Manufacturing a Fixture for Cage & Differential Brake Components

“Designing &Manufacturing of Fixture of cage cum Differential brake”
Chapter-1
Introduction
Presented By Karan Yadav (+91 8329105252) karan.24yadav@gmail.com Page 1

1.1) Introduction:-
Our final year project is one of the most important aspects of our engineering. To see
why, let’s look at a definition of engineering,
“Engineering is that profession in which knowledge of the mathematical,
Computational, and natural sciences gained by study, experience, and practice
Is applied with judgment to develop economically effective use of matter,
Energy, and information to the benefit of humankind.”
Engineering is first and foremost the application of knowledge. However, the
application must be carried out with judgment, to ensure that the resultant system is effective
and efficient, and that it is of benefit.
The final year project is one of the primary the mechanisms used by the college to
provide us with an opportunity to gain experience in the practical, effective, efficient, and
beneficial application of what we have been studying for the past several years. Naturally, we
will continue to gain engineering experience after we graduate but the final year project will
be our first exposure to the full rig our of engineering practice.
It is essential that we learn from this exposure and practice all of the engineering
methodologies involved. It is particularly important that we learn not just to apply what you
know, but to apply it with judgment, with the ability to assess what we are doing and to be
critical of it. There is another reason why our final year project is so important it will
inevitably be used as a discriminator to decide how good an engineering student we are.
1.2 ) PROBLEM STATEMENT:-
A Frequent Changing of Fixture: -The old fixture provided by the manufacturer

of machine is not having the arrangement for machining frames of different diameters on the same
fixture. Fig. Shows the old fixture. It is having spigot plate with only one spigot. Thus, we need to
change the spigot plate and all other components on the spigot plate for every new frame. Assembling
and disassembling of fixtures becomes a time consuming process, thus there is a loss of
productivity.The old fixture is not having the arrangement for avoiding misalignment while mounting
the frame on fixture. Operator has to do the trial and error method for proper alignment. This is also a
time consuming process and possibility of misalignment is more.

Misalignment: -The old fixture is not having the arrangement for avoiding misalignment
while mounting the frame on fixture. Operator has to do the trial and error method for proper
alignment. This is also a time consuming process and possibility of misalignment is more.
1.3) Project Idea
In final year mechanical engineering student have a subject of industrial training. This
subject is essential for the practical knowledge & what happen in industries ?After first
second thirdyear of engineering , students gets a basic and theoretical knowledge about
mechanical engineering, industries and all the trades trending in industries.
The knowledge learned in engineering, it is needed to implement the knowledge by

applying to proper function, to make it more beneficial.
For the project, we have got on chance to do a sponsored project of fixture designing
&manufacturing in “SHRIRAM Industries”in M.I.D.C.Shiroli, Dist. Kolhapur. This
industry uses the up to date machines and trades to produce superior productsof quality. This
industry is also looking forward to international standards by applying the quality circle .This
industryhas a great reputation in market, which deals with very big brands like Mahindra and
Mahindra group.
1.4) Necessity:-
Necessities of this project are as follows
 Reduce the raw material of the product, to make it beneficial.

 Reduce the machining time of product.
 Reduce labor work reduction.
 Improving the quality of product.
 Increasing the efficiency of plant.
This will help the industry to improve the quality of product, improving the customer
satisfaction, increasing reliability of product.

The successful running of any mass production depends upon the interchangeability to
facilitate easy assembly and reduction of unit cost. Mass production methods demand a fast
and easy method of positioning work for
Accurate operations on it.
Jigs and fixtures are production tools used to accurately manufacture duplicate and
interchangeable parts. Jigs and fixtures are specially designed so that large numbers of
components can be machined or assembled identically, and to ensure interchangeability of
components.
1.5) FIXTURES:-
A fixture is a device for locating, holding and supporting a work piece during a
manufacturing operation. It is a production tool that locates, holds, and supports the
worksecurely so the required machining operations can be performed.
Fixtures have a much-wider scope of application than jigs. These work holders are
designed for applications where the cutting tools cannot be guided as easily as a drill.
With fixtures, an edge finder, center finder, or gage blocks position the cutter. Examples of
the more-common fixtures include milling fixtures, lathe fixtures, sawing fixtures, and
grinding fixtures. Moreover, a fixture can be used in almost any operation that requires a
precise relationship in the position of a tool to a work piece.
Fixtures are essential elements of production processes as they are required in most of
the automated manufacturing, inspection, and assembly operations. Fixtures must correctly
locate a work piece in a given orientation with respect to a cutting tool or measuring device,
or with respect to another component, as for instance in assembly or welding. Such location
must be invariant in the sense that the devices must clamp and secure the work piece in that
location for the particular processing operation. There are many standard work holding
devices such as jaw chucks, machine vises, drill chucks, collets, etc. which are widely used in
workshops and are usually kept in stock for general applications.
Fixtures are normally designed for a definite operation to process a specific work
piece and are designed and manufactured individually. Jigs are similar to fixtures, but they
not only locate and hold the part but also guide the cutting tools in drilling and boring
operations. These work holding devices are collectively known as jigs and fixture.
Set blocks and feeler or thickness gauges are used with fixtures to reference the cutter to the
work piece. A fixture should be securely fastened to the table of the machine upon which the

work is done. Though largely used on milling machines, fixtures are also designed to hold
work for various operations on most of the standard machine tools.
Fixtures vary in design from relatively simple tools to expensive, complicated
devices. Fixtures also help to simplify metalworking operations performed on special
equipment.Fixtures are most often identified by the machine tool where they are used.
Examples include mill fixtures or lathe fixtures. But the function of the fixture can
also identify a fixture type. So can the basic construction of the tool. Thus, although a tool
can be called simply a mill fixture, it could also be further defined as a straddle-milling,
plate-type mill fixture. Moreover, a lathe fixture could also be defined as a radius-turning,
angle-plate lathe fixture. The tool designer usually decides the specific identification of these
tools. It, use set blocks and thickness, or feeler, gages to locate the tool relative to the work
piece(as shown in figure).
Fig. A fixture references the cutting tool, in this case with a set block.
Fixtures are normally classified by the type of machine on which they are used.
Fixtures can also be identified by a sub classification. For example, if a fixture is designed to
be used on a milling machine, it is called a milling fixture. If the task it is intended to perform
is straddle milling, it is called a straddle milling fixture. The same principle applies to a lathe
fixture that is designed to machine radii. It is called a lathe-radius fixture.
1.6) TYPES OF FIXTURES:-
The names used to describe the various types of fixtures are determined mainly by how
the tool is built. Jigs and fixtures are made basically the same way as far as locators and
positioners are concerned. The main construction difference is mass. Because of the increased
tool forces, fixtures are built stronger and heavier than a jig would be for the same part.
 Plate fixtures
Plate fixtures are the simplest form of fixture. The basic fixture is made from a flat plate that
has a variety of clamps and locators to hold and locate the part. The simplicity of this fixture
makes it useful for most machining operations. Its adaptability makes it popular.

Fig1. Plate fixtures
 Angle-plate fixture
The angle-plate fixture is a variation of the plate fixture. With this tool, the part is normally
machined at a right angle to its locator.
Fig2. angle-plate fixture
 Modified angle-plate fixture

While most angle-plate fixtures are made at 90 degrees, there are times when other angles are
needed. In these cases, a modified angle-plate fixture can be used.

Fig3. Modified angle-plate fixture
 Vise-jaw fixtures
Vise-jaw fixtures are used for machining small parts. With this type of tool, the standard vise
jaws are replaced with jaws that are formed to fit the part. Vise-jaw fixtures are the least
expensive type of fixture to make. Their use is limited only by the sizes of the vises available.
Fig4. Vise-jaw fixtures

 Indexing fixtures
Indexing fixtures are very similar to indexing jigs. These fixtures are used for machining
parts that must have machined details evenly spaced. The parts shown in
Figure are examples of the uses of an indexing fixture.

Fig5. Indexing fixtures

 Multistation fixtures
Multistation fixtures are used primarily for high-speed, high-volume production
runs, where the machining cycle must be continuous.
Duplex fixtures
Duplex fixtures are the simplest form of multistation fixture, using only two
stations. This form allows the loading and unloading operations to be performed
while the machining operation is in progress. For example, once the machining
operation is complete at station 1, the tool is revolved and the cycle is repeated
at station 2. At the same time, the part is unloaded at station 1 and a fresh part is
loaded.
Fig6. Duplex fixtures

 Profiling fixtures
Profiling fixtures are used to guide tools for machining contours that the
machine cannot normally follow. These contours can be either internal or
external. Since the fixture continuously contacts the tool, an incorrectly cut
shape is almost impossible. The operation in Figure 2–24 shows how the cam is
accurately cut by maintaining contact between the fixture and the bearing on the
milling cutter. This bearing is an important part of the tool and must always be
used.
Fig7.Profiling fixtures
1.7) REQUIREMENTS OF A FIXTURE:-

In order to maintain the work piece stability during a machining process, an
operational fixture has to satisfy several requirements to fully perform its functions as a work
holding device. The following constraints must be observed while designing a variable
fixture:
 Deterministic Locationa work piece is said to be kinematically restrained when it
cannot move without losing contact with at least one locator. The work piece is
constrained by a set of appropriately placed locators so that it is presentable for the
machining operation. Locating errors due to locators and locating surfaces of the work
piece should be minimized so as to accurately and uniquely position the work piece
within the machine coordinate frame.
 Total ConstraintA work piece should be fully constrained at all times to prevent any
movement. Clamps should provide locking forces to hold the work piece in place
once it is located. A totally restrained part should be able to remain in static
equilibrium to withstand all possible processing forces or disturbance.

 Constrained DeflectionWork piece deformation is unavoidable due to its

elastic/plastic nature, and the external forces impacted by the clamping actuation and
machining operations. Deformation has to be limited to an acceptable magnitude in
order to achieve the tolerance specifications.
 Geometric ConstraintGeometric constraint guarantees that all fixture elements have
an access to the datum surface. They also assure that the fixture components do not
interfere with cutting tools during a machining operation. In addition to these
requirements, a fixture design should have desirable characteristics such as quick
loading and unloading, minimum number of components, accessibility, design for
multiple cutting operations, portability, low cost, etc.

Chapter-2
Literature Review

A research has been done in the past to solve the problems. In the paper of ‘fixture
machining process’ a model of modular fixture setup relative to cutting forces is proposed,
planned and assembled. Positioning is discussed and the best solution is offered. Tool
movements influence the final quality of work piece, and fixture influences tool movements.
Primary criterion used for grouping the manufacturing features to form setups is usually tool
approach direction. For load/unload, for pin placements etc. tool carries the main forces that
later form the final shape of the work-piece. The paper of ‘machining fixture design’ presents
development of an expert system for machining fixture design. System provides new fixture
construction design for specified input parameters on the basis of adequate production
guidelines. Paper provides applied methodology, basic structure, specific systems, segments
review, and example of systems implementation in industrial production. In closing, there are
conclusions, developed systems advantages and disadvantages, and directions for future
research.
J. Cecil[5] proposed an innovative clamping design approach is described in the

context of fixture design activities. The clamping design approach involves identification of
clamping surfaces and clamp points on a given workpiece. This approach can be applied in
conjunction with a locator design approach to hold and support the workpiece
during machining and to position the workpiece correctly with respect to the cutting tool.
Detailed steps are given for automated clamp design. Geometric reasoning techniques are
used to determine feasible clamp faces and positions. The required inputs include CAD
model specifications, features identified on the finished workpiece, locator points and
elements.
Michael Stampfer[2] presented a paper which deals with the problem of setup and
fixture planning for the machining of box-shaped parts on the horizontal machining centers.
The setup and fixture planning shown in fig. 2. The central topic of this research is the
automation of the conceptual design of fixtures shown in fig. 3. This topic is deal with the
setup planning.
Shrikant [8] discussed various design and analysis methods in the context of to
improve the life of fixture, different fixture geometries are compared experimentally and are
selected. The proposed eccentric shaft fixture will fulfilled researcher Production target and
enhanced the efficiency, fixture reduces operation time and increases productivity, high
quality of operation.

Weifang Chen [4] developed a multi-objective model was established to

increase the distributing uniformity of deformation and to reduce the degree of deformation.
The deformation is analyzed by optimizing the finite element method. To solve the
optimization model a genetic algorithm was developed. A satisfactory result was obtained by
illustrating an example, which is superior than the experiential one.
Chen Luo, LiMinZhu,Han Ding, in his paper Two-Sided Quadratic Model for
Work piece Fixturing Analysis,2011proposed that presents a novel model for work piece
positioning analysis. Existing fixturing models may
underestimate the positioning error due to neglect of the curvature of one or both contacting
bodies.
S. Kashyap W.R. DeVries in their paper optimization in fixture, proposed with
minimizing deformation of the work piece due to machining loads about fixturing support
positions, especially in thin castings.
Y. Zheng& Y. Rong& Z. Hou in their paper, A finite element analysis for stiffness of
fixture units, proposed a systematic finite element model to predict the fixture unit stiffness
by introducing nonlinear contact elements on the contact surface between fixture
components.
M. Y. Dakhole, Prof. P.G. Mehar, Prof. V.N. Mujbaile , in their paper, Design And
Analysis Of Dedicated Fixture With Chain Conveyor, gives a feasible solution on
conventional roller chain conveyorised arrangement with dedicated moving fixture with
conveyor for the tractor components like rear axle career, bull gear and shaft of a tractor
model.

Chapter-3
Design

3.1) FIXTURE DESIGN FUNDAMENTALS
 Fixture design consists of a number of distinct activities:

Fixture planning, fixture layout design, fixture elementdesign, tool body
design, etc. They are listed in Fig. intheir natural sequence, although they may be
developed inparallel and not necessarily as a series of isolated activitiesin actual
execution.
Fixture design deals with the establishment of the basic fixture concepts:
 Fixture layout is an embodiment of the conceptsin the form of a spatial configuration
of the fixture,
 Fixture element design is concerned with theconcrete details of the locators, clamps
and supports,
 Tool body design produces a structure combiningthe fixture elements in the desired
spatial relationship withthe machine tool.
3.2) FIXTURE DESIGN CRITERIA
The following design criteria must be observed during the procedure of fixture design:
 Design specifications
 Factory standards
 Ease of use and safety
 Economy
3.3) FIXTURE DESIGN
Fixture planning is to conceptualize a basic fixtureconfiguration through analyzing all

the availableinformation regarding the material and geometry of thework piece, operations
required, processing equipment forthe operations, and the operator.
The following outputs are included in the fixture plan:
 Fixture type and complexity
 Number of work pieces per fixture
 Orientation of work piece within fixture
 Locating datum faces

 Clamping surfaces
 Support surfaces, if any
Generation of fixture layout is to represent the fixture concepts in a physical form.
The following outputs are included in the fixture layout:
 Positions of locators
 Positions of clamps
 Positions of supports, if any
 Type of locators
 Type of clamps
 Type of supports
 Clamping forces and sequence
Fixture element design is either to detail the design drawings committed on paper or to create the solid models
in a CAD system of the practical embodiment of the conceptual locators, clamps and supports. It is possible to
use standard designs or proprietary components. The following outputs are included in the fixture element
design:
 Detailed design of locators
 Detailed design of clamps
 Detailed design of supports, if any
Tool body design is to produce a rigid structure carrying all the individual fixture elements in their proper
places.
3.4) FIXTURE DESIGN PROCEDURE
In the design of a fixture, a definite sequence of design stages is involved. They can
be grouped into three broad stages of design development. Stage one deal with information
gathering and analysis. These include product analysis such as the study of design
specifications, process planning, examining the processing equipment and considering
operator safety and ease of use. In this stage, all the critical dimensions and feasible datum
areas are examined in detail.
Stage two involves the consideration of clamping and locating schemes. A clamping
scheme is devised in such a way that it will not interfere with the tools or cutters and are fully
compatible with proposed locating surfaces or areas. The locating scheme, using standard
elements such as pins, pads, etc. is designed to be consistent with clamping and tool-guiding
arrangements. Stage three is the design of the structure of the fixture body frame. This is
usually built around the work piece as a single element which links all the other elements
used for locating, clamping tool-guiding, etc. into an integral frame work. The above
procedures are quite general and can bemodified depending on the relative importance of the
various elements in providing for the required accuracy of the work piece to be located and
secured into the fixture device. With the popular adaptation of modular fixture elements, the
fixture body frame is usually a standard block with fixed arrays of locating and fixing holes
or slots. It becomes a matter of selecting the most suitable body frame to accommodate the
various elements, provide good support of the work piece and access to cutters and tools.
3.5) Design offixture
The General rules for designing are as follows

 Compare the cost of production of work with present tools with the expected
cost of production, using the tool to be made and see that the cost of buildings
is not in excess of expected gain.
 Decide upon locating points and outline clamping arrangement.
 Make all clamping and binding devices as quick acting as possible
 Make the fixture fool proof.
 Make some locating points adjustable
 Avoid complicated clamping arrangements
 Round all corners
 Provide handles wherever these will make handling easy
 Provide holes on escapes for chips
 Locate clamps so that they will be in best position to resist the pressure of the
cutting tool when at work
 Place all clamps as nearly as possible opposite some bearing point of the work
to avoid springing action
For Designing purpose we must consider following parts

 Location
Drilling is a comparatively short operation, thus the location system must be such that
positioning and clamping takes up as little time as possible.
 Clamping
Usually the clamping force will be small, so hand nuts, cams and similar clamping
features can be used. Hand-operated clamps are usually preferred to spanner operated clamps.

 Handling the fixture

If the fixture is turned over from one station to the next, it should incorporates
handles, lifting points or other similar aids, and be made as light as possible.
 Feet
There should be four feet so that the fixture will be unstable if pieces of swarf are
under one or more of the feet.
The feet of a fixture must ensure that the axes of the drill bushes are vertical to
prevent incorrect work or broken Tools.
 Handling clearances
Care must be taken to ensure that there is adequate room for the operator’s hands
when using the equipment.
 Swarf and cutting-fluid clearances
Particular attention must be paid to the removal of swarf and cutting fluid. Provision
should be made for the brushing away of swarf and cutting fluid.

Unfinished Component
Finished Component

Fig. fixture 2D Drawing

Fig. Rest Pad Fig. Cylindrical locator
Fig. Locator fig. locator guide

Fig.Clamping Post 1 Fig.Clamping Post 2
Fig.Clamp Fig.Fixture Plate

fig 3D fixture Drawing

Chapter-4
Concept

4.1) Fixture for VMC Machine
A fixture means of locating and clamping the work piece, and also means of
controlling (guiding) the cutter during cutting.
The work piece is located and clamped, and then the fixture is inverted before the
machining is done. Location is very important to understand the meaning of location before
understanding about the jigs and fixtures. The location refers to the establishment of a desired
relationship between the work piece and the jigs or fixture correctness of location directly
influences the accuracy of the finished product.
The jigs and fixtures are desired so that all undesirable movements of the work piece
can be restricted. Determination of the locating points and clamping of the work piece serve
to restrict movements of the component in any direction, while setting it in a particular pre-
decided position relative to the jig. Before deciding the locating points it is advisable to find
out the all possible degrees of freedom of the work piece. Then some of the degrees of
freedom or all of them are restrained by making suitable arrangements. These arrangements
are called locators.
To restrain the work piece completely a clamping device is required in addition to
locating device and jigs and fixtures. A clamping device holds the work piece securely in a
fixture against the forces applied over it during an operation. Clamping device should be
incorporated into the fixture, proper clamp in a fixture directly influence the accuracy and
quality of the work done and production cycle time. Basic requirement of a good clamping
device are listed below,
(a) It should rigidly hold the work piece.
(b) The work piece being clamped should not be damaged due to application of clamping
pressure by the clamping unit.
(c) The clamping pressure should be enough to overcome the operating pressure applied on
the work piece as both pressure act on the work piece in opposite directions.
(d) Clamping device should be capable to be unaffected by the vibrations generated during an
operation.
(e) It should also be user friendly, like its clamping and releasing should be easy and less time
consuming. Its maintenance should also be easy.

(f) Clamping pressure should be directed towards the support surfaces or support points to
prevent undesired lifting of work piece from its supports.
(g) Clamping faces should be hardened by proper treatments to minimize their wearing out.
(h) To handle the work pieces made of fragile material the faces of clamping unit should be
equipped with fiber pads to avoid any damage to work piece.
4.2) Advantages of fixture:-
The following points are describes the advantages of fixture designing
(1) It reduces or sometimes eliminates the efforts of marking, measuring and setting
of work piece on a machine and maintains the accuracy of performance.
(2) The work piece and tool are relatively located at their exact positions before the
operation automatically within negligible time. So it reduces product cycle time.
(3) Variability of dimension in mass production is very low so manufacturing

processes supported by use of jigs and fixtures maintain a consistent quality.
(4) Due to low variability in dimension assembly operation becomes easy, low
rejection due to less defective production is observed.
(5) It reduces the production cycle time so increases production capacity.

Simultaneously working by more than one tool on the same work piece is possible.
(6) The operating conditions like speed, feed rate and depth of cut can be set to higher
values due to rigidity of clamping of work piece by jigs and fixtures.
(7) Operators working becomes comfortable as his efforts in setting the work piece
can be eliminated.
(8) Semi-skilled operators can be assigned the work so it saves the cost of manpower
also.
(9) There is no need to examine the quality of produce provided that quality of
employed jigs and fixtures is ensured.

Fixture along are specifically designated machine parts, which can be manufactured
by any of the following methods:
(a) Machining, (b) Forging, (c) Casting and (d) Complicated.
Fixtures are fabricated in different pieces and joined together by welding or by nuts &
bolts. Normally fixtures are made of hardened steel, which are wear resistant, corrosion
resistant, and thermally in sensitive. Their dimensional accuracy directly influences the
accuracy of performance of the operations where these are used.
4.3) Work Holding Principles
Locating Principles
A locator is usually a fixed component of afixture. It is used to establish and maintain

the positionof a part in the fixture by constraining the movement ofthe part. For work-pieces
of greater variability in shapesand surface conditions, a locator can also beadjustable
An unrestricted object is free to move in any twelve possible directions. Fig. shows an
object with three axis and planes, along which movement may occur. An object is free to
revolve around or move parallel to any axis in either direction. To illustrate this planes have
been marked X-X, Y-Y, Z-Z, The directions of movement are numbered from one to twelve.
Figure8: Degrees of freedom (DOF) and planesof movement

To restrict the movement, accurately locate a part in fixture. This is done with locaters
and clamps.
 Characteristics of good location

− Minimum locating points should be used.
− Locating points should be placed as far as apart aspossible.
− Locating should be small and size.
In general, three locating forms can be considered, namely plane, concentric, and
radial. For plane locating form, locators are used to locate the work piece on any surface such
as flat, circular or irregular surfaces. For concentric locating form, pin-hole locators are used
and for radial locating form, locators restrict the work piece movement around the concentric
locators. The 3-2-1 principle is the most commonly method used. In this method, three
perpendicular surfaces of the work piece are used to define the locating position.
 Clamping Principles
As the locating is important to restrict the movement of the work piece, clamping is
also important to resist the effects of cutting forces. The direction of clamps should be
determined according to cutting force direction in order to perform machining operations
securely. Clamping forces should be in the same direction of the machining forces which try
to push the work piece down onto the locators and supporters. The clamp should be large
enough to hold the work pieceand small enough to stay away of the cutting tool path. There
are some other factors that should also be considered in use of clamps. These include
machine tool vibration, loads and stresses, damage preventing of the work piece, and
improving loading/unloading speed.
4.4) Fundamental Principles of Fixtures

Fixtures are used for large number of operations. Different types of principles of
fixtures are described below.
 Locating Points
Good facilities should be provided for locating the work. The article to be machined
must be easily inserted and quickly taken out from the jig so that no time is wasted in placing
the work piece in position to perform operations. The position of work piece should be
accurate with respect to tool guiding in the jig or setting elements in fixture.

 Fool Proof
The design of jigs and fixtures should be such that it would not permit the
work piece or the tool to insert in any position other than the correct one.
 Reduction of Idle Time

Design of Jigs and Fixtures should be such that the process, loading, clamping
and unloading time of the work piece takes minimum as far as possible.
 Weight Of Jigs And Fixtures

It should be easy to handle, smaller in size and low cost in regard to amount of
material used without sacrificing rigidity and stiffness.
 Jigs Provided With Feet

Jigs sometimes are provided with feet so that it can be placed on the table of
the machine.
 Materials For Jigs And Fixtures
Usually made of hardened materials to avoid frequent damage and to resist

wear. Example-MS, Cast iron, Die steel, HSS.
 Clamping Device
It should be as simple as possible without sacrificing effectiveness. The

strength of clamp should be such that not only to hold the work piece firmly in
place but also to take the strain of the cutting tool without springing when
designing the jigs and fixtures.

Chapter No 5
COST ESTIMATION

1. Cost Estimation Table:
Sr.No Particulars Qty Rate Amount

1 Fixture Plate (24”X 24”) 1 4000 4000/-
2 Cyl. Locator 1 1200 1200/-
3 Clamp 2 120 240/-
4 Clamp Post 2 80 160/-
5 Nut 2 5 10/-
6 Bolt 21 10 210/-
7 Studs 2 30 60/-
8 REST PAD 7 48 336/-
9 Locator 1 300 300/--
10 Locator Guide 1 500 500/-
11 Total 7016

2. Machining Operation
 Cutting
 Drilling
 Threading
 Grinding
 Material Hardening
 Chambering

REFERENCE

REFERENCE
1) Erik K. Henriksen, Jig and Fixture Design Manual, Industrial Pres Inc.
2) Cyrill Donaldson, George H. LeCain, V. C. Goold. (1999-3rd Ed).Tool
Design Manual Glencoe. Tata, McGrawHill. United States.
3) David Spitler, Jeff Lantrip, John Nee, and David A Smith. (May 2003).
Fundamentals of Tool Design, Fifth Edition. Society of Manufacturing
Engineers; 5th edition.ISBN-10: 087263650X, ISBN-13: 978-
0872636507
4) Edward G.Hofman (1984), Fundamental of Tool Design (5th ed.).Delmar

Learning Drafting series. ISBN: 1-4018-1107-8
5) Herman W. Pollack (1998), Tool Design (2nd Ed.) Prentice Hall
6) Paul. D.Q. Campbell, (1994) Basic Fixtures Design, Industrial Press

Corp. New York, ISBN:0-8311-3052-0
7) Robert A. Malloy (1994), Plastic Part Design for Injection Moulding: an

Introduction, Hanser Gardner Publications, Inc, Cincinati. ISBN : 1-
56990-129-5
8) Smith, William Fortune, (2nd Ed, 1990), Principles of Materials Science

and Engineering, Mc-Graw Hill Int. Ed. ISBN: 0-07-059169-5
9) Engineering drawing and design, sixth edition, Jensen, Helseland Short,

McCgrawhill publications

Designing & Manufacturing a Fixture for Cage & Differential Brake Components

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“Designing &Manufacturing of Fixture of cage cum Differential brake”

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1.2 ) PROBLEM STATEMENT:-

A Frequent Changing of Fixture: -The old fixture provided by the manufacturer

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1.3) Project Idea

The knowledge learned in engineering, it is needed to implement the knowledge by

Necessities of this project are as follows

 Reduce the raw material of the product, to make it beneficial.

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Fig1. Plate fixtures

Fig2. angle-plate fixture

 Modified angle-plate fixture

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Fig3. Modified angle-plate fixture

Fig4. Vise-jaw fixtures

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Fig5. Indexing fixtures

Fig6. Duplex fixtures

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1.7) REQUIREMENTS OF A FIXTURE:-

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 Constrained DeflectionWork piece deformation is unavoidable due to its

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J. Cecil[5] proposed an innovative clamping design approach is described in the

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Weifang Chen [4] developed a multi-objective model was established to

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3.1) FIXTURE DESIGN FUNDAMENTALS

 Fixture design consists of a number of distinct activities:

3.2) FIXTURE DESIGN CRITERIA

3.3) FIXTURE DESIGN

Fixture planning is to conceptualize a basic fixtureconfiguration through analyzing all

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3.4) FIXTURE DESIGN PROCEDURE

The General rules for designing are as follows

For Designing purpose we must consider following parts

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 Handling the fixture

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Fig. fixture 2D Drawing

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Fig. Rest Pad Fig. Cylindrical locator

Fig. Locator fig. locator guide

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Fig.Clamping Post 1 Fig.Clamping Post 2

Fig.Clamp Fig.Fixture Plate

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fig 3D fixture Drawing

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4.1) Fixture for VMC Machine

(a) It should rigidly hold the work piece.

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The following points are describes the advantages of fixture designing

(3) Variability of dimension in mass production is very low so manufacturing

(5) It reduces the production cycle time so increases production capacity.

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